Boiler+Drum+Erection+Procedure

PT. TRUBA JURONG ENGINEERING

LABUAN 2 BANTEN 2 X 300 MW CFSPP PROJECT

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BOILER DRUM ERECTION PROCEDURE

ISSUANCE DATE:

Unit Issuing : Construction Approved By : Site Manager Page 2 of 6 REVISION 0

1. General

The Boiler Drum (166 Tones ) with Hanger (10 Tones) and also rigging

tools (6.5 Tones) is erected to its final location (EL 66800) by using 2 unit

PSC heavy lift jack type L 300 lifting jack with Capacity each unit are

( 110 tones SWL ) in the cases proposed 7 parts 18 mm diameter

Dyform strand cables @ 70 meter long. The detailed preparation work,

erection and final alignment are as follow.

2. Equipment Specification

L 300 Lifting (2 Numbers)

Capacity : each @ SWL 110 MT based upon 7 – parts (from

total of 19 strands) Dyform Strand @ safety factor

2.5.

Stroke : 450 mm.

Câble : 7 Nos .18 mm Strand @ 70 meter long.

Skate Roller : 8 Nos each @ 100 ton mechanical skate rollers.

Hydraulic Control hoses: 2 units of hydraulic control hoses, sufficient for

carrying out above work.

Power Pack : L4/12 E

Capacity : 2 Nos liner at 15 liter

Supply : 415 V 3 phase 50 Hz

System



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Capacity : 220 tones

Lifting rate : 12 M / hours.

Chain Blocks.

Capacity : 5 ton 2 units

: 10 ton 2 units

All necessary spare parts and specialist hand tool to support of lifting.

4. Installation of Equipment.

The actual equipment installation method at site is by 450 tonnes crane

available at site.

The following is proposed:

a) The lifting strands will be delivered to site in coils (approximately 2

tones each) and will be cut to length using disc cutter .The end of

strands will be prepared for threading.

b) The jack base will be tack welded to the jack supports beams

together with the moving skates and the fixed anchor blocks

installed inside their fabrications.

c) The jacks and fixed anchor will now be threaded with their strands

comprising the lifting cables.

d) The complete assemblies of jacks, beams, cables, anchors and

fabrications will now be lifted in to place and secured.

e) The power pack now be positioned at high level and the hydraulic

connections made.

f) The system is now ready for testing and connection to the drums.



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5. Strap Hanger setting of Boiler Drum

Prior to the lifting the Drum, the Boiler Drum strap hangers are set to

facilitate the setting of Drum in its final location. After marking the center

line on roof girder, the strap hanger is set in position and goes along with

the steam drum. The detail is as per Drawing RED-004-CM2-SD-2004.

6. Drum Lifting Details

The length of steam drum is 22150 mm and the span between grid G3

and G5 is 21000 mm. Hence the drum is required to be tilted and lifted to

avoid clashing with steel. On this case, the drum will be tilted at an

inclination of 35 degrees.

The jacks will be mounted on jack support beams which will be mounted

on roller type’s skates. The movement and restrain of beam will be by

chain block. The jacks will be operated from a single electric hydraulic

power pack.

The actual loads on jacks as the drum is hoisted up at 35o is considered

(Lifting load of drum with internals 166t + hangers 10t + rigging tools

6.5t) at jack near grid G5 is 1343.49 KN and jack near grid G3 is 937.76

KN including safety factor 25%.

The following sequence is proposed to clear the steel work on gridlines.

a) Preparatory works such as temporary scaffold access platforms at top

deck steel for jack operators and erectors and other levels’ access for

watchmen at various elevations must be prepared in advance.

b) The lifting equipment will be tensioned up to 25 % increment unit 1

the drum lifts clear its supports.



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c) Drum is lifted up by approximately 100 mm from the present position

and held for approximately 15 minutes while all direct load bearing

temporary and permanent girders and beams, jacking system are

checked for any undue deflections or connections (steel/hoses) non

conformities.

d) Once the system has been cleared for safe lifting, the

wood/steel/concrete block that were supporting the drum at ground

floor are removed using mobile crane, forklift, and chain blocks.

e) The lifting equipment will be tensioned up to 25 % increment unit 1

the drum lifts clear its supports as details attached (3). After removal

of Drum’s support, the drum’s permanent U rod hangers are

positioned on either side of the drum near actual locations secured by

temporary clamping and slings in such a way as to remain vertical

even when the drum is lifted in an inclined position.

f) Continue lifting until there is 1.5 meter clearance beneath the drum.

The Drum shall be raised up in a gradually speed to minimize the jack

effect of the load. It shall be lifted in a horizontal position if possible

and If not it shall be in the position where both hooks of the lifting

device is carrying the load. The angle of inclination shall be on position

where the lifting cable is not its vertical position.

g) Lifting one end (the end with the jack nearest the drum final position

center line) unit 1 the drum reaches an inclination of 35 degrees to the

horizontal. At this inclination, the drum should clear the steel on both

sides. A continuous monitoring on the condition of the lifting system

shall be done. The spotter will continuously following the drum while

on its way up to check for any obstruction along the way of the drum.

If there any obstruction, the spotter should be inform the lifting

engineer to hold the lifting until the obstruction is cleared, then

resume the lifting.



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h) Lift both ends together until 1 the highest end is clear above the + 60.

M level steel.

i) Lift on the lowest end only until the drum is returned to horizontal. At

the same time pull the movable jack support beam away from the

center line to maintain the plumb of the lifting cables.

j) Once drum is horizontal is horizontal continue lifting both end together

until the U – Bolt connection can be made.

k) After U – Bolt installation is complete, transfer the load from the lifting

cables to the bolts by gently bleeding the system down.

l) The lifting device shall dismantled together with the temporary

support to clear the way for the erection work to progress,

Note during the lifting the power pack operator will monitor the individual

jack loads .In addition; the operator will need to be in contact with the

lift co-coordinators and spotters watching the drum clearance as it

passes each level.

7. Final Alignment of Steam Drum

After the drum is set in position, the below mentioned alignment is carried

out to confirm the centering of drum along X and Y axis .Details in

attachment (4).

a. Rolling.

b. Elevation of Drum.

c. Level of Drum.

d. Drum Centering.

The steam Drum shall finally alignment first before the connection of any

pipe on to it. Alignment shall be checked and confirmed in the following

manner.



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1. Check the X and Y axis of the drum centre line if it coincides with the

line previously established. If not adjustment shall be made to the

position of the drum by pulling to the direction where there is a

negative variance, until be come zero variance. This shall be done on

all direction where there is a difference with the lay – out

2. Check the final elevation of the drum horizontal axis.

3. Check the leveling of the drum .This shall be done by checking the left

and right end of the drum along the horizontal axis of the drum and

also on both end, front and rear side of the drum respectively. Make

sure that the position of the drum is as per lay out and accrue level.

8. General Notes:

1. Manning scheme for lifting of Drum shall prepared after reviewing

thoroughly by personnel relevant to the works, and the procedure shall

be carried out under careful verification in safety at every step.

2. Area within the lifting works shall be roped off with safety marks rope

and notice board denoted “KEEP OFF EXCEPT PERSONEL CONCERNED”

shall be putt there.

3. Lifting tools such as wire rope /strand, chain block etc shall be checked

firmly in advance and confirmed thoroughly that no any defective point

exist.

4. Sign to Jack operator shall be given only nominated person shall be

handling winch only by sign his sign.

Documents

Boiler+Drum+Erection+Procedure